Bottom flap folding and conveying apparatus

ABSTRACT

A pair of axially extending horizontal conveyor surfaces are provided with a space therebetween which accommodates a bottom flap folding and conveying apparatus. Stationary support members which are on the same horizontal level as are the conveyor surfaces accept the incoming product for packaging. A movable carriage having a downstream supporting portion and an upstream combination support-folder pusher plate portion operates in the axial direction through the utilization of an air or hydraulic cylinder and carriage track. After a carton is placed over the product the bottom end flaps are folded upwardly in a manner which positions them adjacently underneath the product. The upstream bottom end flap is folded by the combination supportfolder pusher plate which not only folds the flap but causes the carton and product to be moved axially toward the output conveyor surface while supporting a portion of it. The downstream bottom end flap folding means can be either movable or stationary.

United States Patent Bell et al.

[ 1 July4,1972

[54] BOTTOM FLAP FOLDING AND CONVEYING APPARATUS [72] Inventors: Jack T. Bell, Olympia, Wash.; Barton K.

Smith, Winnetka, ll].

[73] Assignee: Weyerhaeuser Company, Tacoma, Wash.

[22] Filed: March 29, 1971 [21] Appl. N0.: 128,789

Primary Examiner-Travis S. McGehee AltorneyPatrick D. Coogan, John M. Crawford, Stuart A.

Heller and Bryan C. Ogden [57] ABSTRACT A pair of axially extending horizontal conveyor surfaces are provided with a space therebetween which accommodates a bottom flap folding and conveying apparatus. Stationary support members which are on the same horizontal level as are the conveyor surfaces accept the incoming product for packaging. A movable carriage having a downstream supporting portion and an upstream combination support-folder pusher plate portion operates in the axial direction through the utilization of an air or hydraulic cylinder and carriage track. After a carton is placed over the product the bottom end flaps are folded upwardly in a manner which positions them adjacently underneath the product. The upstream bottom end flap is folded by the combination support-folder pusher plate which not only folds the flap but causes the carton and product to be moved axially toward the output conveyor surface while supporting a portion of it. The downstream bottom end flap folding means can be either movable or stationary.

9 Claims, 6 Drawing Figures PATENTEDJuL 41972 SHEET 1 0F 5 FIG 11 JACK T. BELL BARTON K. SMITH CINVENTORS ATTORNEYS PATENTEDJUL 41972 3.673.764

sum 20F FIGO 3 5 T T m l7 I8 40 4| 44 43 45 lo I 9 l 3 29 l3 I4 25 4 40 18 4| 4244 4 JACK T. BELL BARTON K. SMITH INVENTORS ATTORNEYS PATENTEDJUL 4 I972 3,573 75 sum 30F 3 JACK T. BELL BARTON K. SMITH 'INVENTORS ATTORNEYS BO'I'I'OM FLAP FOLDING AND CONVEYING APPARATUS BACKGROUND OF THE INVENTION This invention relates generally to a mechanical apparatus for automatically folding an adjacent pair of bottom end flaps in an appropriately slotted and scored container blank. More particularly it relates to the device on which a product is placed, over which the partially erected container blank is placed and whereby the bottom end flaps are folded to a position under the contained product.

In the art there have been many suggestions for folding the bottom flaps of a standard carton. Several examples of automatic bottom flap closure machines may be seen by referring to the issued U.S. Pat. Nos. 3,442,063, 3,426,502, and 2,252,435. Each of these patents discloses a machine which provides means for folding the bottom flaps of cartons. However, the folding means are either pivoted arms engaging the flaps while the carton is stationary or fixed elements closing the flaps in response to movement of the carton by a conveyor.

When packaging a delicate product such as brittle sheet material, or fragile ceiling tiles, it is desirable to position the product at a packaging station and then place the carton over the product so that the fragile product will not have to be placed in the carton. With a delicate product it is desirable to handle it as little as possible during the packaging operation.

After a canon has been placed over the product, it is then desirable to provide an automatic flap folding machine which operates without handling the product in a severe manner. It is also desirable to have a flap folding machine which is quick in operation and simple in structure so as to allow easy repair when necessary.

Accordingly, from the foregoing, one object of the present invention is to automatically fold the bottom end flaps of a container which has been placed over a product.

Another object is to fold the flaps without causing the product to move relative to the container.

These and other objects of the invention will become aparent upon reading the following specification in conjunction with the attached drawings.

SUMMARY OF THE INVENTION Briefly, this invention is practiced in one form by positioning a pair of stationary spaced-apart supporting surfaces at a packaging station in a horizontal plane which is generally equal to the horizontal plane of input and output conveyor surfaces. Extending from the ends of the supporting surfaces are axially extending lateral open spaces for the accommodation therein of the bottom end flap folding means. Operating within the space between the supporting surfaces and the axially extending space upstream from the supporting surfaces is a movable supporting surface which is in operative communication with a fold-push plate member. The fold-push plate member serves to fold the upstream flap and then push the carton axially downstream toward the output conveyor surface. Operating within the axial space downstream from the supporting surfaces are means to fold the downstream end flap.

BRIEF DESCRIPTION OF THE DRAMNG FIG. 1 is an isometric view showing the product on the input conveyor, a product having a carton surrounding it at the packaging station, and a carton with product having the bottom end flaps properly folded on the output conveyor.

FIG. 2 is a similar isometric showing the packaging station of the present invention.

FIG. 3 is a side sectional elevation taken along lines Ill-III of FIG. 2 showing the movable carriage in the carton receiving position.

FIG. 4 is a front elevation view taken along the section lines lV-lV of FIG. 3 in order to show the tracking arrangement of the movable carriage.

III

FIG. 5 is a view similar to FIG. 3 showing the movable carriage in its extended position.

FIG. 6 is a paru'al side elevation view showing an alternate embodiment for the movable carriage.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to FIG. 1 a suitable environment for utilizing the packaging station, or bottom end flap folder which is generally indicated as 1, is depicted. A suitable product 2 is shown atop the input conveyor surface generally indicated as 3. Atop the output conveyor surface generally indicated as 4, a standard cardboard carton indicated as 5 is shown having the bottom flap 6 and bottom rear flap 7 still in their downwardly extending positions. The downstream bottom end flap 8 and upstream bottom end flap 9 have previously been folded inwardly at the packaging station 1. Within the cardboard carton 5 is the product 2.

The input conveyor surface 3 is comprised of a plurality of rollers 10 which are divided laterally by an axially extending open space indicated as 11., Open space 11 is provided for the accommodation of a portion of the mechanism operating at packaging station 1 as will be more fully described later. Of course the rollers 10 are mounted on a suitable axially extending frame member 12. In a very similar manner the output conveyor surface 4 is comprised of a plurality of laterally extending rollers 13 mounted in a suitable axially extending frame member 14.

Other suitably spaced vertical leg members 15 are provided to establish the proper vertical position for the packaging station 1 and conveyor surfaces 3, 4. Also provided as part of the over all supporting frame are a pair of axially extending frame members 16 which provide a base for several of the elements at packaging station 1.

Referring now to FIGS. 2-5, the details of the packaging station 1 will be described. Packaging station 1 is positioned between the downstream end of the input conveyor 3 and the upstream end of the output conveyor 4 and spans an axial distance which is slightly greater than the longer dimension of the cardboard carton 5. The vertical dimension for the packaging station 1 extends between a horizontal plane between the input conveyor 3 and output conveyor 4 and the axially extending frame members 16. This vertical dimension is of course sized in order to accommodate the dimension of the downwardly extending flaps 6, 7, 8 and 9.

Extending upwardly from the axially extending frame members l6 and positioned approximately in the center of the axial space between the conveyor surfaces 3, 4 are a pair of spaced apart stationary support members generally indicated as 17. Of course the function of the stationary support members 17 is to provide a plane on which the product can rest while it is at the packaging station 1. Each support member 17 has a horizontal axially extending top surface 18 for this purpose. The plane of the top surfaces 18 is generally in the same horizontal plane as are the horizontal planes formed by the tops of the rollers 10 and laterally extending rollers 13. In this manner, of course, as a product is conveyed down the input conveyor surface 3, it will move directly onto the spaced apart support members 17 and their attendant horizontal top surfaces 18. Likewise, after a carton has been placed over the product and the bottom end flaps 8, 9 folded, the carton and product will be transported axially in the same horizontal plane toward and then over the output conveyor surface 4. The lateral spacing between the support members 17 is provided for the same purpose as is the axially extending lateral space 11 between the rollers 10; that is, to provide travel distance for a movable carriage to be described subsequently.

Mounted on the outside vertical surface of each support member 17 is an axially extending flap support V" member 20. The flap support members 20 are adjustably mounted through a suitable bracket member 21 such that each support member 20 can be vertically adjusted to accommodate flaps of different dimensions. The flap support members 20 extend axially a distance which is approximately equal to the axial dimension of the horizontal top surfaces of the support members 17. By so limiting this dimension it will be appreciated that all other moving elements will clear the support members 20 while the support members still provide suificient vertical support and placement for the upwardly extending sides of the carton 5. An additional desirable feature of the spaced apart support members 17 which is depicted in the Figures is the provision of an inclined upstream lateral surface 22 for each of the support members 17. The inclined lateral surface 22 is provided to facilitate axial movement of the carton 5 after the upstream bottom end flap 9 has been folded upwardly. It will be appreciated that afier flap 9 has been folded the box 5 and product 2 will necessarily be conveyed over the top surfaces 18, and by providing the inclined surface 22 the edge of flap 9 will pass more smoothly over the top surfaces.

The moving elements utilized to fold the bottom end flaps 8, 9 at packaging station 1 will now be described. The downstream bottom end flap folder is generally indicated at 23 and is comprised of a pivotally mounted flat folder plate 24 which is adapted to pivot about a laterally extending axis indicated at 25 which is generally at the same vertical level as is the horizontal plane of the top surfaces 18. Operatively connected to the folderplate 24 through a downwardly extending connector member 26 is the ram 27 of a horizontally extending pivotally mounted air or hydraulic cylinder 28. The cylinder 28 is pivotally mounted through the pinned connection 29 at its base end to a suitable mounting bracket 30 which extends upwardly from one of the frame members. Likewise, at the opposite end the ram 27 is attached to the connector member 26 through a pinned connection 31. The flat folder plate 24 is mounted at the laterally extending axis 25 on a suitable supporting base 32 such that when the cylinder 28 is actuated it will turn the folder plate 24 from its downwardly extending retracted position through an angle a such that it then lies in a generally horizontal plane at the same vertical level as are the top surfaces 18. It will be noted that the laterally extending axial space between the axis 25 and the downstream ends of the top surfaces 18 is sufiicient to allow the downstream bottom end flap 8 to extend downwardly adjacent the folder plate 24 when it is in the retracted position. Of course, it will be appreciated that all of the bottom flap score lines of the carton 5 are generally in the same horizontal plane as are the top surfaces 18. In this manner when the folder plate 24 is actuated the downstream bottom end flap 9 will be folded upwardly about its score line to a generally horizontal position under the packaged product 2.

Although a movable folder plate 24 has been described to fold the downstream bottom end flap 9, it has been found that such a movable element is not needed in all cases. Other suitable downstream flap folding means include simply the stationary end of the output conveyor surface 4. With such an embodiment the motivating means for folding the downstream flap 8 is provided by the movement of the carton and product as it leaves the packaging station 1 and travels onto the output conveyor surface 4. The downstream flap 8 will automatically fold about its score line as the carton and product move axially over the upstream end of the output conveyor surface 4. The primary embodiment, however, does utilize the movable folder plate 24 in order to provide a positive folding action.

In order to properly fold the upstream bottom end flap 9 to a horizontal position underneath the product 2, an axially movable carriage is provided which is generally indicated at- 33. Themovable carriage 33 is comprised of two operatively connected elements. The downstream movable support carriage 34 is hingedly connected through a hinged connection 35 to an upstream, vertically displaceable axially movable combination movable support--folder pusher plate carriage 36. The position of the carriage 33 in FIG. 3 is its retracted position where a laterally extending axial space extends between the downstream carriage 34 and upstream carriage 36 such that the upstream bottom end flap 9 can be positioned within this space as the carton 5 is placed over the product 2.

It is movable carriage 33 that operates within the axially extending open space 11 in the input conveyor surface 3 and the aforementioned space between the pair of support members 17.

The movement of carriage 33 is confined to a generally horizontal axial direction by a suitably mounted carriage track indicated at 37. The carriage 33 is adapted to move axially along track 37 through mounted roller wheels 38 which are suitably confined laterally to run along track 37. One set of roller wheels 38 is mounted on each of the carriage sections 34, 36. The carriage track 37 may be conveniently mounted by fixing it to the axially extending frame members 16 which may be seen by referring to FIG. 4. The carriage track 37 extends axially in a horizontal plane a distance which is between a vertical plane extending through the downstream end of the top surfaces 18 and a vertical plane extending through the downstream end of the input conveyor surface 3. At the horizontal position corresponding generally to the point where the vertical plane through the downstream end of the input conveyor surface intersects the track 37, it begins a curvilinear sloping portion indicated as 39. The slope of track portion 39 is indicated as angle B on FIG. 3 and is on the order of 40 from the horizontal. The upstream carriage 36 is mounted on the carriage tracks 37 such that when the movable carriage 33 is in its retracted position, its uppermost portion will be at a vertical level which is below the horizontal plane of the rollers 10. This position is of course realized because the wheels 38 of carriage 36 are resting on the sloping portion 39 of track 37.

Positioned at the top of the downstream movable support carriage 34 is an axially extending movable supporting surface 40. The supporting surface 40 is in a horizontal plane which is at a vertical position slightly below the top surfaces 18. Of course the supporting surface 40 is sized laterally such that it will move axially within the space between the top surfaces 18 without contacting any part of either support member 17. At the upstream end of supporting surface 40, there is positioned a pair of rollers 41 in order to facilitate the movement of the product across the top surface 40 and onto the support members 17 as it comes from the input conveyor surface 3. Also provided at the upstream end of the supporting surface 40, is a downwardly curved portion 42 which provides smooth movement of the carton 5 and product 2 from the packaging station 1 to the output conveyor surface 4.

Mounted atop the upstream carriage 36 is an axially extending combination flap folder-supporting surface 43. The main portion of the combination surface 43 extends axially in the same horizontal plane as that defined by the supporting surface 40 when the upstream carriage 36 is traveling on the horizontal axial portion of carriage track 37. This position may be seen by referring to FIG. 5. Extending in a downwardly curved direction from the axially extending portion of combination surface 43 is a curved portion 44 which is utilized to initiate the folding action for the upstream bottom end flap 9.

Extending upwardly from the upstream end of the combination surface 43 is the carton pusher plate 45. The top end of pusher plate 45, as previously mentioned, does not extend above the horizontal plane of the rollers 10 when the carriage 33 is in the retracted position.

Providing the axial movement for movable carriage 33 is a horizontally mounted axially extending actuating cylinder 46. Extending in an upstream direction is the actuating ram 47 which is fixedly connected at connection point 48 to a downwardly extending connection bracket 49. Connection bracket 49 is, of course, securely fixed to the downstream carriage 34 to provide positive movement for both carriage members 34, 36. The cylinder 46 is selected so that the attending ram 47 will cause the downstream carriage 34 to move axially a distance from the retracted position to a position where the upstream end of the downwardly curved portion 42 of movable supporting surface 40 will be a short distance downstream from the upstream end of the top surface 18. The travel of the upstream carriage 36 provided by the ram 47 is such that it travels up the curvilinear sloping portion 39 of the carriage track 37 and an axial distance such that the carton 5 and product 2 will be pushed by plate 45 a distance suflicient to allow the output conveyor surface 4 to take up the conveying motion of the canon 5. The partially extended position of the carriage 33 which represents a partially retracted position for ram 47 may be seen by referring to FIG. 5 of the drawing.

It will be apparent to one skilled in the art that the movable carriage 33 can take different embodiments. For example, the carriage 33 could be comprised of a pivoting yoke 50 as seen in FIG. 6. The yoke 50 pivots about fixed point 51 by the action of the same cylinder 46. Comprising yoke 50 is a downstream leg 52 on top of which is mounted the movable supporting surface 53 which corresponds to movable surface 40. An upstream leg 54 has combination movable supportfolder pusher plate means generally indicated at 55 mounted at its top. Combination means 55 is of course analogous to the combination surface 43 and pusher plate 45. A spacer and support member 56 extends between legs 52, 54 to provide the same laterally extending axial space as was described for the principal embodiment.

The ram 47 is pivotally connected at point 57 to the upstream leg 54 and causes the yoke 50 to pivot in the direction indicated by the arrow on FIG. 6. In the retracted position, which corresponds to the retracted position of carriage 33, a carton S can be placed over the product as it rests atop the surfaces 18. On actuation the combination means cause the flap 9 to be folded upwardly and the carton 5 to move axially downstream while at the same time the movable supporting surface 53 moves downward through its natural arc to a position slightly below the top surfaces 18 as seen by the phantom lines in FIG. 6.

OPERATION OF THE INVENTION Assuming that a first product is to be packaged the product 2 will be conveyed along the input conveyor surface 3 and automatically onto the top surfaces of the pair of spaced apart support members 17. A portion of the vertical support for the product will be provided by the supporting surface 40 of the downstream carriage. The axial dimension of the product to be packed is such that its downstream side extends slightly over the downstream end of the horizontal top surfaces 18 while the upstream end extends slightly over the upstream end of the downwardly curved portion 42 of surface 40. The lateral dimension of the product corresponds generally to the lateral dimension between flap support members 20.

When the product is positioned as above, a human operator will position a carton blank over the product with the bottom front and rear flaps 6, 7 positioned in the support members and the upstream and downstream end flaps 8, 9 extending downwardly from their respective score lines. The proper vertical height relative to the score lines for the bottom flaps is provided by the proper positioning of the flap support members 20.

The human operator now actuates the flap folding and conveying cycle by pressing any suitably mounted actuating button indicated at 50. The actuating cylinders 28 and 46 are connected in parallel and as a result the first to be actuated is the one providing the least resistance which is cylinder 28, thereby actuating the folder plate 24. This action folds the downstream bottom end flap 8 up through an angle of approximately 90 where it is positioned under the product. The cylinder 46 is then actuated causing the combination flap folder-supporting surface 43 to turn the upstream bottom end flap 9 through an angle of approximately 90 to a position which is under the product. The axial distance between the downstream end of the input conveyor surface 3 and the upstream end of the support members 17 is suflicient to allow the flap to be folded. Of course, as flap 9 is being folded upwardly by the action of upstream carriage 36 the supporting surface 40 is moving axially downstream slightly below the product 2, thus in eflect, removing the supporting surface.

After the upstream carriage 36 reaches the axial portion of carriage track 37 the combination surface 43 will be positioned under the flap 9 and will provide support for the adjacent carton and product. As the carriage continues to move axially the pusher plate 45 will contact the upstream lateral side of the carton and push it axially a distance sufficient to allow it to come under the influence of the output conveyor surface 4 and be conveyed to the next station in the packaging process.

In the alternate embodiment of the downstream flap folding means, it is apparent that as the pusher plate 45 moves the carton and product axially the downstream flap 8 will automatically be folded about its score line to a position under the product. The operation of the alternate embodiment for the movable carriage 33 is apparent when referring to FIG. 6.

While a detailed example of the principal embodiment together with a brief description of two alternate embodiments has been described, it is understood that many further changes and modifications may be made in the above described bottom flap folding and conveying apparatus without departing from the spirit of the invention. All such modifications are intended to be included within the scope of the appended claims.

What is claimed is:

1. A combination folding and conveying apparatus for cartons having downwardly extending end flaps comprising:

a stationary support surface being generally in a first horizontal plane and defining a first axially extending lateral space,

folder means axially movable within said first axially extending space and adapted to fold an upstream bottom flap to a position normal to its downward position,

pusher means operatively communicating with and extending upwardly from said folder means to a position above said first horizontal plane and adapted to engage said carton and push it axially downstream at substantially the same time said folder means folds said upstream flap, whereby said canon and said folded upstream flap travel axially over said support surface, and

means to motivate said folder means and said pusher means axially toward said stationary support surface within said axially extending space.

2. The apparatus as in claim 1 further including means to fold the downstream bottom flap.

3. The apparatus in claim 2 further including:

an input conveyor surface positioned axially upstream from said support surface and generally in the same first horizontal plane, defining a second axially extending lateral space for the axial travel therein of said folder and pusher means, and

an output conveyor surface axially spaced from the downstream end of said support surface and generally in the same first horizontal plane.

4. The apparatus as in claim 3 in which said downstream flap folding means is comprised of a pivotally mounted folder plate positioned laterally adjacent said output conveyor surface and adapted to turn upwardly to a position which is substantially in said first horizontal plane.

5. The apparatus as in claim 3 in which said downstream flap folding means is comprised of the laterally extending upstream end of said output conveyor surface.

6. The apparatus as in claim 3 further including a pair of axially extending flap support members positioned on the outside of and vertically below said support surface adapted to support said canon in fixed relation to said support surface prior to the axial movement of said pusher means.

7. The apparatus as in claim 1 further including an axially movable supporting surface operatively communicating with but axially spaced from said folder and pusher means and which is positioned in a second horizontal plane slightly below said first horizontal plane and travels axially within said first axially extending lateral space.

8. The apparatus as in claim 7 in which said folder and pusher means and said axially movable supporting surface operatively communicate with each other through a device comprising:

a pivotally mounted yoke member having two upwardly extending legs,

said folder and pusher means mounted atop the upstream leg of said yoke, said movable supporting surface mounted atop the downstream leg of said yoke,

means to pivot said yoke through an angle whereby said folder and pusher means move vertically and axially downstream causing the upstream flap to turn and said carton to be pushed downstream over said stationary support surface and said movable supporting surface moves axially and vertically downward to a position below said first horizontal plane.

9. The apparatus as in claim 7 in which said folder and pusher means and said axially movable supporting surface operatively communicate with each other through a device comprising:

an axially movable carriage member having a hingedly connected downstream portion and vertical displaceable upstream portion,

said movable supporting surface mounted atop said downstream portion,

said folder and pusher means mounted atop said upstream portion,

tracking means for said carriage arranged so that said downstream portion moves axially while said upstream portion moves axially and vertically, and

means to move said carriage axially such that said pusher means moves vertically upward above said first horizontal plane and axially within said second axially extending lateral space while the folder means turns the upstream flap inwardly normal to its downward position, while simultaneously said movable supporting surface travels axially within said first axially extending lateral space. 

1. A combination folding and conveying apparatus for cartons having downwardly extending end flaps comprising: a stationary support surface being generally in a first horizontal plane and defining a first axially extending lateral space, folder means axially movable within said first axially extending space and adapted to fold an upstream bottom flap to a position normal to its downward position, pusher means operatively communicating with and extending upwardly from said folder means to a position above said first horizontal plane and adapted to engage said carton and push it axially downstream at substantially the same time said folder means folds said upstream flap, whereby said carton and said folded upstream flap travel axially over said support surface, and means to motivate said folder means and said pusher means axially toward said stationary support surface within said axially extending space.
 2. The apparatus as in claim 1 further including means to fold the downstream bottom flap.
 3. The apparatus in claim 2 further including: an input conveyor surface positioned axially upstream from said support surface and generally in the same first horizontal plane, defining a second axially extending lateral space for the axial travel therein of said folder and pusher means, and an output conveyor surface axially spaced from the downstream end of said support surface and generally in the same first horizontal plane.
 4. The apparatus as in claim 3 in which said downstream flap folding means is comprised of a pivotally mounted folder plate positioned laterally adjacent said output conveyor surface and adapted to turn upwardly to a position which is substantially in said first horizontal plane.
 5. The apparatus as in claim 3 in which said downstream flap folding means is comprised of the laterally extending upstream end of said output conveyor surface.
 6. The apparatus as in claim 3 further including a pair of axially extending flap support members positioned on the outside of and vertically below said support surface adapted to support said carton in fixed relation to said support surface prior to the axial movement of said pusher means.
 7. The apparatus as in claim 1 further including an axially movable supporting surface operatively communicating with but axially spaced from said folder and pusher means and which is positioned in a second horizontal plane slightly below said first horizontal plane and travels axially within said first axially extending lateral space.
 8. The apparatus as in claim 7 in which said folder and pusher means and said axially movable supporting surface operatively communicate with each other through a device comprising: a pivotally mounted yoke member having two upwardly extending legs, said folder and pusher means mounted atop the upstream leg of said yoke, said movable supporting surface mounted atop the downstream leg of said yoke, means to pivot said yoke through an angle whereby said folder and pusher means move vertically and axially downstream causing the upstream flap to turn and said carton to be pushed downstream over said stationary support surface and said movable supporting surface moves axially and vertically downward to a position below said first horizontal plane.
 9. The apparatus as in claim 7 in which said folder and pusher means and said axially movable supporting surface operatively communicate with each other through a device comprising: an axially movable carriage member having a hingedly connected downstream portion and vertical displaceable upstream portion, said movable supporting surface mounted atop said downstream portion, said folder and pusher means mounted atop said upstream portion, tracking means for said carriage arranged so that said downstream portion moves axially while said upstream portion moves axially and vertically, and means to move said carriage axially such that said pusher means moves vertically upward above said first horizontal plane and axially within said second axially extending lateral space while the folder means turns the upstream flap inwardly normal to its downward position, while simultaneously said movable supporting surface travels axially within said first axially extending lateral space. 